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Communication Problem

10/18/2013 5:01 PM

I need your feedback if you can:In our power plant there are 16 gens, which run on according to the load demand receiving from field. For the communication there is parallel fiber optics looping from two groups of gens 1 to 8 and 9 to 16. The Data from the field is getting received on Mode bus (ModLon II Gateway ModBus® - LON Converter) between mode bus and PLC (Schneider CPU 43412A) there is Processor Adapter, which helps to make better communication between PLC and Modebus. And PLC shows all the Data on HMI. HMI is windows based (Windows 95). Since last three months all the communication is showing very rubbish behavior. After every 15 days it start creating wrong errors during the load on the system and which make trouble. And due this all the control system become hang, and to make this okay the only solution is to reset everything, and this is very much problematic during the running on full load, what's my and my team finding. It could be due to:
• Communication cable laying with HT cable with 16 to 18 inches distance.
• Method of laying cable cause stressing.
• Lose Connection issues (wire & Connector)
• System battery voltage not stable.
• Over Heating ModLon and other devices.
• Process adopter N520 loses connection.
• Process adopter N520 malfunctioning.
• Windows Registry over flow.

We are still looking the issue, Can you please add your suggestion.

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#1

Re: Communication Problem

10/18/2013 5:35 PM

Well guessing can only go so far, at some point you must troubleshoot step by step....I'm surprised you don't have an error log to start from....or do you? 15 days running time before problems start, is this like clock work? If so, this would seem to me to rule out component failure, and more likely to be a communication or software problem...

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#2

Re: Communication Problem

10/18/2013 6:38 PM

first off, I do not know but......I do know a little about how to troubleshoot a problem. so lets look at your data and ask a question or two. you say after "resetting" it makes everything"ok" then look at the list of possible problems you listed. would "resetting" change the stresses on a cable that was already laid? would resetting your system repair a loose or otherwise faulty connection? probably not. you mentioned possibly overheating several devices, get a non contact thermometer and eliminate this possibility and remove the thought from cluttering your problem solving efforts. you also mentioned Win 95, I assume you don't work at the Smithsonian so I might suggest at the very least you have an onsite back up system that utilizes a different operating system so you can always quickly eliminate the OS as a potential source of problems. best of luck

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#3

Re: Communication Problem

10/18/2013 7:06 PM

Can you tell how can error file trigger to next if 1st files memory already filled in win95. whats the location? is it in registry folder? see its not in 15 days fixed. 10 to 15 days. and its happened with both groups of gensets. or if some other possiblity?

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In reply to #3

Re: Communication Problem

10/18/2013 9:16 PM

Well I don't know how you have it set up, but your error log is a txt file and it would be hard to run out of memory....if it's full I would dump the existing files(or archive to a separate drive) and start over so you would know whats happening.....and make sure it's enabled...You should have a program that monitors all controls and gives a readout of any faults....if you have logging enabled it should be printing to a file....You can have a separate hard drive that archives the readout from day to day operations, if you are generating that much data...

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#5

Re: Communication Problem

10/18/2013 11:18 PM

To better help you, a sketch of the system would be great. Use something like CorelDraw!, Visio, Adobe Illustrator, or even Inkscape (Inkscape is a free, open-source vector graphics program. Basics can be learned quite quickly by most people.). You could even use Microsoft Paint.

Once you have drawn the sketch, Save As or Export it as a .bmp, .jpg, or .png file (I think .jpg is best), and use the (Insert Image) icon to get the file from your computer and insert it into the text of your next reply.

Unless a systematic troubleshooting approach is used, you could spend a great deal of time trying to find the problem. Please post a sketch of the system?

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#6

Re: Communication Problem

10/20/2013 4:47 PM
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#7
In reply to #6

Re: Communication Problem

10/20/2013 7:30 PM
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#8

Re: Communication Problem

04/24/2014 2:28 PM

What about the "black box" that records the "traffic" of communications between all system components=sub systems?

What about a monitoring system to each sub system?

Good luck

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